7

PLANT LAYOUT

Introduction (factory site),the factory building is constructed

selectionof
plantlocationarrangement of various departments inside the
problem of area covered by walls and
Afterthe site. The availability ofthe floor Because
selected
aries
only afterthe
constructedlaccordingto thelayout planning. and plant
the
at building building is departments, production process
atory factory administrative building.
Howeve,
requiretments of the contruction offactory dsimultaneousely.
ros. bearing on are considered:
certain(utilities) have direct
and plant layout withthe technical
factory building factory is considered
sevices thatboth external view of the expertise is used by the
Wecan
say
and good deal of
architectural design departments. A
existing plants. The use of expertise
from
The of various for new or It deffers
requirements
service a proper layout
of layout for all plants.
pattern
managementsto
there are not set industry to industry.
nedessary because to location and from
location
Dantto plant, from
Meaning and Definition different facilities including
arrangement of of the production
optinum arrangement
refers to an It is the
overall
racks, sub-stores,
Aplant layout material etc. equipment,
equipment, handling production in
in,machine, toolroom, material facilitating the
e, storeroom, all other aCcessories required
for performed inside
operations
employee services and co-ordinating all and costs of
for changed
the factory. It is a master blueprint
implemented cannot be easily decision. A poorlayout
the plant. Since a layout once
plant layout is a strategichandling, more scrap and
SuCh a change are substantial, the material plant Layout
wlresult in Continuous losses in terms of high design
analyse and performed both at
need to
Te-Work, poor Space utilization etc. Hence, function that hasto be development and
Can hardly be
a
emphasised. It is a crucial growth,
the time of over and during its
initial design of any facility, and arranging
diverAccorsficat1odnin. g
to Thomsori, "A plant layout
involves planning
in
completely neW
the first time order tointroduce
anufacturing machinery,
Dants. It also equipment, and services for
already in usein
Imethods involvimprovements
es
and
the improvements in layouts
in manufacturing
procedures."
 PlantLayout
112
Plant Lay
Keith and Gubellini have defined plant layout as "plant layout deale.ddtion process, plant size, plant location
arangement of physicalfacilities and the manpower which are required to manualem occurs because ofdesion.
aproduct or perform aservice".
many
1. Change in product developmentbul
s d ings, 113
including:diversif cation etc. The yout
According to J. Lundy, "plant layoutideally involvesthe allocation of space and e 2. Introduction of new product
facitities
arrangement of equipment in such a manner that overall I operations costs be 3. Obsolescence of
In the light of above, we can say that alayout is one which allows
minimum 4.Change in
demand
materials rapid
and directly for processing. This reduces transport handling, clerical and other e 5. Market changes
down per unit, space requirements are minimised and it reduces idle machine and i 6. Competitive cost reduction
man time. 7.Frequent accidents
8. Adoption of new safety standards
Objectives of Good Layout 9. Decision to build a new plant.
According to Madeheim,the main objectives of layout isto combine labour wh
physical properties of a plant (machinery, plant services, handling equipments) in si CharacteristiCS of Plant Layout
a manner that greatest output of high quality goods and services manufactured at t: Following are the features of Plant layout:
lowest unit cost of production". Plant layout is intended to fulfillthe following fundaments 1. Plant layout is the physical arrangement of planned industrial crowth.
objectives, which are also criteria for an ideal layout : 2.In implies the preparation of the entire selting for functioning of plant
1. Providing enough production capacity. desonat
to produce the specified goods or services.
2. Overall simplification of production process in terms of equipment utlzain 3. It is concerned with designing the building with alterations and arrangements
minimisation of delays, reducing manufacturing time, and better provision fo sufficient and suitable tohouse the plant equipments.
maintenance.
3. Overallintegratión of man,materials, machinery, supporting activities and anyote order4. ofIt work
is concerned with placement of machines in asystemait sequence as per the
planned.
consideration in a way that result in the best compromise. 5. Plant layout makes arrangement for tools, appliances, stores, materiais required
4. Minimisation of material handlingcost by suitabily placing the facilities in the bes
flow sequence. for operating the machines.
5. Saving in floor space, effective space utilization and less 6. It is concerned with making arrangements for minimurm material handling.
6. confusion. storage facilities for material (a-maternais
I. It makes arrangements for adequate
Increased output and reduced inventories-in-process.
7. Better supervision and control. and finished goods.)
8. Better working environment, safety of
employees and reduced hazards. O. Plant layout makes arrangements for packing finished products instanty ara
9. Worker convenience, improved
morale and worker satisfaction. moving them to warehouses.
provisionfor maintenance
10. Minimisation of waste and higher 9. allows ease of maintenanceethrough making
11. Avoidance of unnecessary capital productivity. faclitiesPl(rooms
ant-layoutetc.)
12. Higher flexib1lity and adaptability toinvestment. 10. It provide ease of supervision.
13. Facilitate coordination and face-to facechanging corditions. makinggodlayout.
communicatjon where appropn
11. It
ensuresefficient use of labour in the plant by
14. High material turnover
through shorter operating cycle.
15. Decency and underliness inside
the plant area.
16. Better customer servicesthrough cheaper and better productsupplies according
Factors Affecting Layout activities.The
for allbusiness industy,
used
There is no pattern of layout be
which can locationandindustryto
to the delivery promises.
patern oflayout setvaries from plant to plant,locationto tyçedependsona
of aparticularbeinggivenbelow:
When Does Need for Plant Layout
Arise?to overall
DiMurfemrebernt oftypes of layout are in use and the
selection
affect the
layoutare
The problem of plant layout should be seen in relation
includes many other functions such
plant design which
selectionof
factors. Some of the factors which

as product design, sales, planning,

 movement 114
and which srocesses
these man1pulation
mobile vhich,
Jar1ousnstalled of mustlocker whether after
requirements should lurn, demand and fromlayout product stationary;,
a Inthe ight, layout industrial
Pipelines equipment.
heavy
equipments, proper solid, and
handling
layout.
workers (ii) ()
factorelements these
process
4.Employee keeping
Typereceive
3.
determine size The the somelayout.
b ig Type
2.
should be light Type 1. by
To To during ratios
which,
roonms Employees-The
they
begin
offor sales
requirements
of
In in cases, In or
arelation are
concerns storage or
stationary; move move toselected. and
move: the elements and of ofdue and
facilities,remain in of with
th e
product
a plant. the but small,
a of used cranes, heavy, of
the the are management
Machinery-The equipment, demand Product--The
majority
as Materials--Plant
process
to
in
men, consideration.
in turn, public
employees.
mind
the
the The same machinery in
to liquid planned towhich rooms
product
product Before
be various stationary their type the th e transportiron trolleys small
or
stationary
materials
are influences
facilities Such product. determines requirements also of way, of or
of used
laying ways particular layout of that manufacture
the other and cases, solid after heavyuse and or
fromproduction.
and as women If layout. theexercises
policy
health or for sifactors t ype etc. large.
work
the depends
orout
and
In the type influence designer area ze me n
the an d bearing ype
materials
The
workers fixed machines. the
determines
of requirements.
moving,
and workers
Hence, of the light
a
of of are it s of ore, depend
raw layout The
station Various plant, course a
on
plant
product, the some layout athe loconnotives
volume of product ofposition
product-that in
as the also
related should experts storage
product. product productionmoved crude raw-maeistorageof is
materials,
from to their layout. min d upon
to
work work
location isIt These
alternatives
relative the
of the
size the
layout
influences
services,
are
employed, also production
influence of meant to moves in oil influenced
necessary Production significantly. The are
space, should the relation the etc. the
productionelements volume
and
station,
station of deserves
in
are the costs type
positionconsider the on for product. and from particular is, It type
feeding the and be in whether th e is
to of the opinion the heavy a station work totherefore,
keeping availableplant toand is of its the
work determine activity, may the the Employee layout. layout
production, and of the other and
plant
considered
consideration
ship-building, t he overhead
materials USed of
and on
employees, type, therefore Thus, handling type
the
station; in combination
the machinery be
related that product plant,
which
determining productioncombined The must facilities layout. positiontheg ,essentalcranes of
achines locationin productishe
which satety, position a in prodin
,the work
tz a to
equipren mat er
will ratio the servCs be plant the The planing are Plamt

in are
be of ano totyp that planned whic h. di plati t T
" In be tou, s, ard
layo: aug so

intgOeysruexpansi
ianalCOnst
The layout. ct io n. on neConcern. Ol Third, aretmat
or
ruckserials buithelding more while choulprodductsindustries
Continuous
industries,
(b) n am(a)ely: Condi
Ext ract t
ivi
( o
vAnal
e.
) nin(i y
g;
) Synt
tic al
(1)
an;
dheti()
c; U5.sed in (üi)
proces ocation. PLantyout
() (following

extent
b) (a) policies:
ngManagement
The The
equi p ment
volume are present If theplant
tO
demand gas. requiraed are mode thanplanning keep the This
the may forAlso, The plant pressed and of one
The
Locat whi cio
h, n-The
6.

end-product in as.
ot

cmanuflasactifiucraIentitoenrmit ent
of s
Each
th e
of Industries exercise Type plant.
in of
a lo
Flayout
The,
move
layout into turn, stlaayoutndar. dised
t r ansport a ti o n,
market inway. mi
and
or
ing of some of urban
whiuctchures.effected
anfuturebe
layout la
lo
yout
cation
to First, th e
industries;
above Industsignirfyic-antThe
this a
context
or
the

s-Management
mation;
productmanageri
ular
a io n a l
st r
would
expansi
site
is by
o n
must must
ma y plan inthefluences site type different is
service.
shoulbed plant. seltehected Contnatofiunre.uous
based t y pes ar angement worker
selected,
The addi ng consi d er
provi de dependiIn ng the size industry and of influence
may
type and
and be in fl u ences det e rmi n ed
provi d e a In and for component
It s the on
industries be tof th e
nent;provision required po
number few some la yout . is
broadly industry of
one the for
cases, upon the the needl aindndust
e ss ries method on machinmachi es ne
expansiofon more the s the in cases, Second,terrailocatn ion the
for plant
for policies standoreys requirement plant storage part the water the todifferent of
on may classifiedlayout. shouki to
expansiOsin;gnificantly whi c h, wi ng exact met
uni nhtod
e r u pt e dl y be and
byrailroads di s ta nces the of of
determiinne beto ofthisofthe tylopeading location the plant aemphasiofse manufacture.
may layout. the
further the
be
into product,
turn, effected the Ipower fa
fuel , fuel of are
from
site the machi nes four mcthod planned
influenceinfluences the existingvil agerequitransport a t i o n and used,
det ein
rmiof
flu
n ences
e
manuf a ct u ri n g that classified
type by generatsiteiowhetn.rement
her sunloading inthe plant th e produce
the and The types:
the
of to
suit
which
plant singladdieof ngorey is
-st somesOurce its
layout assemblformer e into
the is
the
mat the
e ri al
layout. plant more Fourth, be s selected, it
requirfacied. litieothers, det ermi n es
s of typelayout process
one two manufact u ri n g
alternative held
Coal, thof desi g ner or type
e raw of in two them types, at 115
of the
 116
inventory. cost principles.Principles objectives.
understanding athned
While Layout of
handling, minimisation a influence
proper efficient.
layout. Benefits
Layout of intensive fixed and the the factors This sequential
made distance
An The 7. workmen
at 6. 4. 3.
5. principle 2. ofurban of 1. The Personnel
policies. ) (e) (d)
Purchasing
It (fpolicy;
ideally capital workmen. It Principle
Principle Principle soPrincipleofPrinciple
minimum to materials The accepting scopeobviousthatis Des1re
importance Principle
use have between These discussed factors
reduced Operating of that order.
of an investment, of so Principle
laid
production efficient available the should it ofthe of for
cost. ofthat
of should of of adopted This handling. of principles the those rapi d
personnel out flexibilityintegration-There final operations
efficiencies, of safety sequence-Machinery
receive plant
plant layout minimum they usage-Every foot principle selected many
layout a facilities. not also layout in minimum top delivery
reduces delays by
feel
be the are: above, activities. top
and top so layout, management
such on would
avoiding
investment-The The planned Theconsidcration
satisfied. looks process best is as management of
equipment and the layout influence
layout well travel--Men
to layoutThe goods
manufacturingavoidance as
manufacturing achieved avoid the
econonies be installation integratedshould availablelayout.
should
on of
better should the layout to
equirements and waste policies
basis
contain be in in
the policies customers;
of
bottlenecksappreciated
pernnit towns
a product
operations and designerchoice designer
in of
layout harmonious
and space of
costs function:
the the of labour
materials
thatdetermine
revisions the built and
through
and necessaryshould compact.
cost comfort in cities should layout,
should of
of have must
reduced it if should and a
al
handlingl
- of one
makes with provisions fusion should particular a the
have
reduced these result
and where be and time bearing e
understands facilities be plant
in it the effectively
of be a
efforts and travel guided clear
- Smooth covenience for
in least all land arranged layout
materials
depend
materials, the type on plartl
process savibut ngs difficulty safety relevant is should mi nim ise the
lpant'
and
by costy. utlist shot layout. by
handled; B
comt
dbg
on and the in: ero n
the plantfol ow. The PLlanytDut
an in of 1d ha
to be of a
wilayout
th ofwastageresults the
capacity, process
these
Purpose ce
Conducted ensure
J.
to De the management. t
mateelriiamlsi,nates schedules.
quality 4. Pl a nt
heto of
prompt 3.
dat
wor
h a
e
n
k
d
a
ls
n
ep
d
eci
maf cn ufact
madu
e ri
servicplesanning areas.n g planetmploys The
c
1.
Mi nim i sat ion o b Minimisation
jec tives
a
tic aproduct
7. previous advantages.
Mi
O
ni m um Improved theOpt imum and handl i ng to
is Good
production
inadequate
quisite a bottlenecks
floor
of AVOIwheredancemachinDalesance better the ofspoiled suchlayout execut
of

or at Ofte n, io n areas in
and
layout
order Efforts therefore,
mat er i als cut
down costs la yoad
ut va n t a g
50e s
use operatioisns advant
of causes is or
the area. subsequent materials different
and quality qual
output ity work a the
properl y . is ages
wor ker s
basis
right
of
upon good typebottlthese
storage in ves t m ent-In ves
of and
lo t
catim
o n,ent
by control.
si gnificant deadl
and of orders.
stages noist delays delays--Repeat
in e
of ofor that should of the not accounton
operat
they area--Every answer to this material common
e d of advantaare ges

enecksdelays-Bottlenecks planned control-TiContmelyributes

areAll

whiolc-hPiroonductiaton may operat

oduct
tend
spaceions. pileto minimum belofow
job may therefore
Some
factasor datesEvery
handle must cost. a50,re 000
or
be ,byfor, of
the in
machin e manufact ure. short age in for
assignmentpersform be telhe itmheminhandl
steps to
at ed. ing-Nearly makes al ideal
Long concerned. to an
to
ld rol right overprcoome
buicont ductbeioBotn tlelownecks or handling expectations. theto themanagement
or up
delivery orders achi e vi n
for
g made
inch
question atdistance
materials the
nolayout
time speedproduced loadir on execut io n t imely mul t ip le of all. Some plants,
speedy of for tothe But, cynic handlA ing. difference
isation and acontnd roschedul l es, equi p ment
distances,g. ideal Toofspace, An
execut io n of
should
an d
fu l
a
th is make plant how movement in s 30 irrespective
of
are

provides at is an thcaused
with onare
e ratesat or A
execut
ensureorders ion production nefunct w ions; bestfactory, amay Every perthese inoutlined
arned asonabl e nedefficient part ofany plant thby to good can layout long-distance of custotrmers ut i li sat io n e nd use area
concer y are: of is to sashould y cent
advantages so
far ofthe in
the congestion, e be qualit y, avoi d effort
keepdevelopment loscation valthue able, materials the should, 40 thparagraphs
wil orders to th at
rocedures. plant byplace
of speed,
in stal mi
atin
oim
n is ed provides beoforders. of
to
asage;
cost. wiltah yout. i n adequat
the e in
layout orders.
inspectmeaniion gful An are to wil the available handl in g
cheapest
be per e
and
control Athe accidoperat
ents ors. less aprovides of by for movements ideal athe thlebe abour
equi pment
of
speci al y
ed centapplicability
have avoithderefore, whether
are:
pr ogoodduction pro rduct
apid ion inspection bug-a-boo
delivery of area depends of 117
officers plant machine generplalnned should when layout result force.up-to to
beway
and the that
and The than al of by in
 ways: 118
products. stationed
is
production. moved
The
the another
made
milling
like type Layout
Types of organisation. are possible that AThe good
factory.
desirable good Enabling handled
(b) (a) 8.
The product
sequential groups. 4. 3. 2. 1.The
of 1. 5.Static Plant (iv) (iii) (i) ()cheerful 10. the
earnings.
Increased 9.
plant
on machines,Process
typical
at
for
the area.operations
Combined
Celluar Process
Product
following layout
ReducedBetterBetter Improvedindividual
time plant Maximum Deternmining Better
utilisation
to In
particular
the
a has
basis
Thus
In Layout Fixed
or
employee Moraleon: and
depends
working ofefficiency
layout of a layout
Layout,
Layout,
isupervision-A
arrangement arrange such purpose
arrangement a this layout-It has number each
dominating of cutting
all are
Layout are confident. operations, s, the
production labour layout,forging
or
Position a employee worker is therefore,
supervisor tothe
grouped Group or Line
Functional the bearing conditions;
the point. machines one
of popular facilities;
of number
is
of role. several
This operations. of wil also Hybrid
Processing accidents; This management
themachines operations Layout is of
the the be Technology
at
called
on
morale--Employee effectively the the
state ofthe
machines operations type The products done etc. one Layout of
types all labour-Labour
process of go0d
machine Job-shop these. factors first get
on of product
to In in
inthfunctinal
location
e
or
of of workers
the process the this one Layout Flow-line plant mental liesin step full a layout
plant
in may
engineering spent and
the basis differ is group Layout. in inview to
process given type share area in
layout. flow utilising
the layout: condition effective
on good
process of is and Layout. be
from
of more
layout, productive of is of
secondary generally, process All morale
the paid
prcesssuitable machine a allshop materials supervision. the better
layout
section
product the machines supevsoN ensures
the is utilisation for entire
will
lathes layout, time
vwill rather to towithprocess but to vital is every by
Consideration be achieved
operations. for
be
job
like
performing
makeclustered
not placedi to handlino plant
SupervisOr a
product.
than the will e.g., the produdive of houri
as order labour.
under: rathernecessa its be all success when at
onSo, tmachi
ype nes and in. spents t
Plant

tul
tha inlaue si and
U e d pu
d

LaPlanytout
PRODUCTproces ingProducint 'A
fferentoptimum principles:
materials.
movement of
The () ()
2. 1. (iv)
Advantages--The
acilitates
ducts
It Like
use ThereThere
drrangement
The
)
e
PRODUCT A
product
departments
of
shouldshould
distance (LATHE oAECEIVING the and
Product
installed
can the layout manner
be
bebetween
be of
flexibility convenience
capacity.
made
process
convenience
it must machines O-0--0-0-o0
PRESSING
shown
as
'B'
elimininatelasyoutlocatedbedepartments Fig. OFFICEAREA with
without MILLING intheir
productthe ion. for of (grouinProcess
g) : SERVICES following
figure:the
avails materials.
in
thesupervision. differential
changes duplIticataccordance
ion the shou': st -0-0-0-0-0-PRODUCT B
is following oulLayout
d o-o-0-o

inmore be CUTTING sequence

be
the of with shorter done
rangementflexibleadvant
machinesages the
to SHIPPING
sequence
than
according
avoide FINISHING
PRODUCTA wil
be
and : routed
ofline
a of long to
enabioperat
es ions.
machinle.ayout.
the
distancefolowing for
119
the
 120
Product require in more present the the loading
Work-load ofthe product is as forquantity in inspection of increases betweenthe capacity
processes. arise. the flow.balancing.line The
production
the this also
process product In machines required 2.the (vii) routing,
supervisors (iv) line-balancing
(i)
(ii) Disadvantages-The () 5. 4. Liproductionke 3.
(vl) (vi) (v)The Specialization
Individual
'product
Bfrequent
' suítable type known Product The Due
at this at line expansion
More of It The The the The
a type each on of scheduling,
the is cost is cost to product
wil is
forgiven pointgiven
is are by production inspection
required
investmentsprocessing
bewith the lined as
layout th e
layout--In products space not are lack capacity
changes stage
of arranged of of incentive
as continuous where layout, various up, "the
particular of possible required supervision material in of layout,
shown the secondary the ofproduct-line
seen in
is the is atcost production.straight supervision in
the production the required
manufacturing. despatching planning each time not is
separate in primary the
machines inparticular to in schemes breakdown th e of
in in product.
order a this implement atincreases.
inventories. handling following
the machine
flow-production product product each stage is line
importance motorcar sequential type for increases
and prolonged
arrangedin
following
independent importance required layout" process
internal
So
sequence becomes
of process
andcontrol
set-up. needs
called
is
is
must All
layout, the
of
Due increases the are can
dominatingproduction. machines follow-up.
the due the be
figure: in its be by Inline section. storing, becomes unit. process. to which problems
developed. rigid
The relation line its this but the group to ofmain possible. one
wiservices.
th and balanced. specialist frequent
producttypical
few balancing. manufacture.
layout, notmachines as reservoir
due production, sequence
the
over To incentive reduces disadvantages of machine
items Thus, to make necessarily required difficult to
arrangement lines the process the The one supervisors
changes long-routing bottleneck
are
product. of unlike process, this
process product arranged The of due the it does and
for
production. machine tomaterialsschemes is
the layout
best-known balancein to inventory
in impossible fixed
the the complexities th e and of not
in
Product of Product of goes and and the interrupty rated
the process must the successful, straight in on machine waiting
It
getting the th e and more process
througn the turnover back-trac Capat
Plantla
machines doeslayout
layout,remain
Sense exampk sequen
particuia provision basis
to
hee
A manta
and that eve line. arising numb set-u and
not
is ui al a a

points. operations. line :

PLalanytout
(i) of () (ii) One(i)of Following
ma(ii)y Reduced
v)Advantages-The
r Line
Mechanisation Materials Machine
()
PRODUCT
line
RECEIVING
cing toolsPrinciples
le material should MILLING PRODUCT
production or o-o-+o-o
pproduct equipments
be should
matehandling
rial placedshould
miduenate layout beFig. OFFICEAREA --0-0--0
PRODUCT B
handling cost at kept : SERVICES
to
due is
the not must Product CUTTING
lrtenecks
r
advantisegeousto point crossthe be d
in

and stpossible placed minLayout

and raight-line
near while
eedier idle due asanotthe her theatgrouping MILLING SHIPPING
PRODUCT A

capacity. producttoion assembl

under: y line point
vement handiing line. nearmachines FINISHING

flow. the
of between
sequence for 121
materia produ
 labour. between
balance
them. 122
Manufactuing 3.Space
Time
Mechanisation 1.
Floor 2. the line, flow. rated in storing.scheduling, frequent supervisors.
interim
Handling
Material of Pointsof
Difference them (vi) Over(vi) Maximum(v)
Effective
line. (vi) it (v) (iv) Disadvantages--The
(ii)
capacity, (ü) () (xi) (x) (ix) (vii)
They is As The The The It
It Maximum
ifficult thUnlike
If
e
sometime facilitates
is despatching changes
Effective Effective
Comparison there breakdown production duplication relatively
are entire
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